Assignment:

• Providing a monitoring system that makes reliable records and facilitates absolute transparency of operational on-board data.
• Displaying performance reserves or bottlenecks in the distribution network well ahead of time.
• Contractor: Shipyards Meyer-Werft and Lürssen

 besecke's Solution:

• Developing the besecke BDE-control system. BDE-control is an innovative system that permanently displays – on mega-yachts, for instance – the energy consumption and process flows, is able to detect promptly unforeseen operational anomalies in the provisional networks and thus optimizes the vessel's operations to run efficiently.
• Lürssen's yachts have, on board 120 sensor point stations that measure and report status and are absorbed by the system – from the power management to fire protection, from tender doors to the pH-value in the swimming pool.
• • All processes can be traced back through the database systems, by having them exported as CSV files and transmitted via a remote connection.

Customer Advantages:

With the help of the BDE-control system, the economically efficient optimization potential can be detected more easily and utilized more quickly.

• At the same time, the system will help to avoid stress situations well ahead of time. This reduces maintenance expense and increases operation times.

The software solution is suitable for all technical standard components and can anytime be extended by adding new applications.

Assignment:

• Development of an automation concept for all zones to be monitored and controlled. These include, for instance, the vessel's engine, generators, door positions, fire extinguisher valves, fire detectors, NMEA data, security, filling levels, operating hours, alarm services, untreated wastewater, helicopter pad, windlass, power management (EPMS), HVAC, video monitoring (CCTV), maintenance system and entertainment
• Challenge: to process quickly an unusual large amount of data and make results available anywhere anytime. Such action requires an extremely high computing capacity without increasing the number of controls.

besecke's Solution:

• Implementation of 125 programmable and particularly efficient Wago Ethernet controllers that collect and bundle the information overload as decentralized controls
• Layout of a pervasive Ethernet structure from the field to management level – on basis of an Ethernet-ring that combines all controllers
• Deployment of the collected measurement data for processing and visualizing within the central Monitoring Control System (MCS) designed by besecke – via an OPC-server (designed by besecke), which processes data at a sixfold speed of the products available in the general market
• Development of the controller software – for instance, for power distribution and security monitoring – and a standard program for acoustic alarms which is less prone to failure
• Providing technical support over the entire operating life of the yacht

Customer Advantages:

• There is no need for any sophisticated redundant server structure and cable paths.
• The highest degree of security and system availability; since each controller works independently and failures have no impact on the integral system

The system's modularity allows for an easy and quick upgrade of individual modules – when changes are needed

Assignment:

• The absorption refrigerator system utilizes water as refrigerant and lets it evaporate at 3–5 degrees Celsius. The system drains the evaporated refrigerant and guides it back inside the closed water cycle. During this thermal process, the energy guzzling compressor to be used for cooling is no longer required.
• The aim of the shipping company and the shipyard was to produce a Megawatt of the cooling medium for the refrigerated holds and air-conditioning – from two Megawatts of the heat loss that would originate from generators.
• besecke's assignment was to design the entire software and to commission the on-board system.

besecke's Solution:

• besecke's software regulates the entire system, compiles comprehensive alarm and event lists and sends the collective alarms to the overriding automation of the vessel. Always present: an automatic and regulated shutdown in the case of a failure.
• Specialized controllers on board store more than 100 readings, alarms and status messages.
• What's so special? The visualization software allows for all values to be displayed in the web-browser and provides for direct transfer of the performance documentation to the shipyard and shipping company.

Customer Advantages:

• The following becomes obvious after the testing stage: both the system and software also function on the high sea and respond to a large demand for cooling.
• besecke's pioneering work can therefore be applied to other application areas, thus, setting a significant milestone to energy savings by land and sea.

Assignment:

• Development of the state-of-the-art system for the passenger on-board infotainment and security and remote monitoring systems (the present version is controlled using touch-sensitive input devices and based on sequential control of the scenes in all zones)

besecke's Solution:

• Projection of the entire plans for the electronic systems on board via an IP-network, including the TV, along with the video-on-demand and audio-on-demand solutions, passenger information, internal communication, lights and air-conditioning control, and with respect to the implication of alarm and fire alarm systems within the visualization
• Integration of an Operation Management Center (OMC) as the central station to monitor and control all IP-based systems
• Alignment of interfaces with all other systems on board
• Detailed construction, delivery, and installation of all system components, including the corresponding cabling and software
• Providing training for the crew, maintenance and service for all supplied systems
• Admission of other board systems into the IP-network – e.g. the automation

Customer Advantages:

• An ideal interchangeable interaction of the systems
• Uniform visualization and individual control of all system components, on request by customer, based on various parameters (time, position, hotel and security status, etc.)
• A smooth connection to the available on-board systems and extension of the IP-network by adding other applications

Assignment:

• Development and realization of the facility plans in cooperation with the Kraft Foods' staff
• Implementation of the freeze-drying facilities as part of the near-complete automated production processes of the factory
• Ensuring a permanent temperature of –50°C inside the vacuum dryer and adjacent grinding and sifting chamber is maintained, while the extreme temperatures are prevented from developing the thermal bridges between the building's walls and ceilings
• Project participants: SIA Besecke from Riga and besecke assembly teams from other parts of Europe

 besecke's Solution:

• Development and projection of nearly the entire electrical engineering and control electronics
• Construction under the application of the extreme freeze-resistant vacuum dryer Konrad, being the center of the freeze-drying facility
• Construction of dozens of electric cabinets in Bremen and their transport to Gorelewo, including installation
• Assembly of all components and commissioning of the entire facility on site
• Complete cabling, partly using meter-wide cable paths to sustain the working temperature and insulate the heat of the building

Customer Advantages:

• An extensively automated location that meets the utmost quality requirements while
  • it continuously maintains its annual production at 10,000 tons of instant coffee without interruptions
• Direct access to the Russian market – the second largest market for instant coffee in the world
  
  

Assignment:

• Installation of the P17 production line in the largest Frosta factory in the fishery port in Bremerhaven. Its operation ranges from having deep-frozen ingredients delivered directly from the raw materials warehouse, mixing and preparing recipes inside the tumble drier, to packaging and stacking of finished dishes onto palettes. The final station of the P17 is the fully automatic deep-freeze high-level storage, where the palettes are stalled for shipping.
• Special challenges the management control of such complex facility has to conquer:
  
  • The deep-freeze chain process may never be interrupted.
  • The pre-defined mixture ratio of ingredients in a recipe must be dosed exactly for each serving.
  • Each serving must have the same weight.

besecke's Solution:

• Planning and construction of a process-control technology, which is based on the following two components:
  
  • a computing system that manages the production, and
  • an operating and monitoring computer that compiles data to visualize, monitor and manage all processes.
• Programming interfaces with the overriding databases and computing systems. These feed the system with all important information, such as the production rules, recipes, etc.
• Developing visualizations on touchscreen monitors. In case of a failure, this feature enables Frosta's employees to intervene with the production process at any time and on any station.
• Wiring and assembling electric cabinets for Frosta and other companies participating in the P17 project
• Assembling and commissioning the facility on Frosta's factory site

Customer Advantages:

• An ideal functional interaction of all links in the factory and with external suppliers

Assignment:

• Installation of an ultramodern coffee roastery, which is able to refine six tons of coffee per hour
• Contractor and project partner for the plant construction and engineering: PROBAT – a worldwide operating roastery specialist from Emmerich
• A special challenge: in spite of the persistently prevailing hard-working circumstances on site, there was no room for delays. This was not because of the fixed completion deadline but mainly due to the strictly limited residence permit in India. No besecke employee was allowed to stay for longer than 180 days.

besecke's Solution:

• Construction site management, together with PROBAT – including the search for and acquisition of machines and materials locally
• Assembly of the roaster, mill and silos, some of which were 15 meters tall
• Assembly of the air-compressor system
• Projection, realization and commissioning of the entire electrical technology and automation

Customer Advantages:

• A swift and reliable project handling based on a trusting relationship with PROBAT, which has been maintained for decades, plus the global expertise with regard to the construction of coffee-roasting facilities which evolved over time as a result

Assignment:

• Installation of six barcode-labeling stations that would automatically label each finished palette or providing for labeling by hand with an EAN-128 label.
• Administration by each station of up to nine production lines – to process the labeling order anytime anywhere

besecke's Solution:

• Implementation of a central database with an interface to the overriding ERP-system. The new or finished labeling orders are forwarded/reported via interface back to the labeling station
• Equipping each station with a Siemens S7 SPS controller barcode printer, industrial panel PC-operating station, and a scanner unit
• Programming the labeling system with the modular Wonderware system platform software

Customer Advantages:

• Highly efficient implementation of the labeling stations with the modular software system for all required interfaces
• Nearly unlimited extension options as to the software functions
• Realization of future extensions within a standardized software architecture, which is more secure as to the planning and the cost, as opposed to in-house solutions
• Optional adjustment of licensing models, based on individual demands and requirements – either by providing a specific number of client access logins, due to the changing access dynamics or by defining a fixed number for specific workstations

Assignments:

• Development of an Automated Guided Vehicle (AGV) for the Factory Logistics The vehicles moving on a magnetic rail are fed information – as to what task they are supposed to execute where – with the information originating from a chief PC and the so-called RFID-tags. The RFID-tags are a kind of a wireless label, which can be read wirelessly when a reading device passes by – even if several yards (meters) away.
• Development of a Facility for Ventilation and Aerification of Paint-Finishing Lines For this purpose, electric powertrains with a performance output of up to 250 kW were implemented as part of the production process – halfway through the production hall up to 28 meters.

besecke's Service:

• Construction and programming, in close agreement with the plant management
• Assembly and commissioning in the factory

Customer Advantages:

• A quick realization of new production specifications by making a complete besecke team available – consisting of programmers, electrical engineers, electricians and a mechanic.
• The top-quality assurance by obtaining assistance from an expert team, with a long-standing Volkswagen experience, that is thoroughly familiar with details of the production facilities.

Assignment:

Development of a control technology solution based on the Wonderware application server – with the aim of

• documenting and visualizing the entire assembly line 1,
• aggregating all visualizations that already exist in one application,
• archiving and analyzing all failure alerts and alert data through database support,
• integrating special search functions for users,
• enabling a vehicle tracing,
• displaying data concentrator information, and
• extending the production data information system (ProDis) while setting it up for the future.

besecke's Solution:

• Visualization of the whole system via decentralized view clients.
• Re-engineering of the SPS interfaces to the Siemens' SPSs, which are in place according to the VW standard.
• Integration of the SPSs into the application-server-solution, creation of device-integrated-objects (DI-objects) for the galaxy, and the commissioning
• Extension of the intranet-based information portal "ProDis" to facilitate access via web-browser to the actual and historical facility information.

Customer Advantages:

• Reusability, thanks to the development and deployment of logical and graphical templates. If, for instance, graphics must be altered at a later point, the templates can be used as often as necessary.
• Conceptual design as a multi-user system: multiple users can work within the same data galaxy.
• Optimization of performance, thanks to a divided system build-up that can be extended without limits: if, for instance, problems occur at some place, individual platforms can be unloaded while others make the objects available again.
• Individual menu navigation on View-Clients: the strict segregation of the logic and graphics allows for adjusting each View-Client to users' needs – provided these are part of the administration group.
• Immediate and uninterrupted availability of all information: the VW maintenance staff is spared long communication paths through different production halls and is given the opportunity to check the overall status by directly monitoring the assembly line 1.

Assignment:

• Development and construction of a fully automatic high-racking storage system warehouse, which would save storing space and enable quick consignment of more than 10,000 palettes full of goods
• External dimensions: 45 m (length) x 35 m (width) x 42 m (height). Number of racks: 16
• Supplying a system that would store and pick palettes with the help of automated rail-guided vehicles that would serve the whole warehouse
• Project partner for the mechanics: Westfalia Systemtechnik GmbH

besecke's Solution:

• Drafting plans, together with the end customer and partner company
• Electrical engineering of 2 automated guided vehicles, along with approximately 100 meters of conveyor technology
• Programming the automated guided vehicles, conveyor technologies, and security control
• Assembly of the electric cabinets
• Preliminary commissioning in a testing facility
• Cabling and commissioning of the system on site
• Providing instructions and training to Markus Kaffee's operating staff

Customer Advantages:

• A highly customized solution, which also keeps in check all economic aspects, in addition to the technical details.
• Time and cost savings for the customer through the preliminary commissioning of the vehicles in the testing facility. The work on site is reduced, the system gets deployed earlier.

Assignment:

• Modernization of the on-site facility that has been used for measuring, analyzing, sawing, and reporting
• Special challenges:
• due to the age of the facility it was not possible to refer to the documentation or program codes
• the entire renovations were to be realized during the production break, within merely three weeks.

besecke's Solution:

• Building a completely new control technology on the basis of the operating cycles that have been recently known
• Programming and building visualization – also, with the help of Knauf employees and their experience they gained over the past decades
• Integrating the S7 control concept because no spare parts were partly available for the existing technology until that point
• Deploying the latest light grid and ultrasonic displacement sensors made by Turck to saw the supplied tree trunks to a production-conform length
• Completely disassembling the facility's previous electrical systems, installing new electric cabinets, control panels, and field wiring
• Performing test-runs and commissioning the facility and providing instructions to the Knauf employees with respect to the "new" production

Customer Advantages:

• High cost savings and sustainability due to the preservation of the previous facility – while simultaneously optimizing the work processes

Assignment:

• Development of the control system program for unloading of train cargo at the train unloading station, a differential loading of eight dome silos, and unloading of silos at two ship loading stations.
• Development of a uniform visualizing and operating system that will integrate all processes that are usually processed at the terminal – even those that are not controlled by besecke technology (e.g. the lighting or the dedusting plant).

besecke's Solution:

• Programming and partial construction of the controlling technology which removes cargo quickly and safely from the train, moves it through silos and onto the ships – in their respective quality and quantity
• Installation of the visualization technology on basis of a redundant server system made by Siemens, with an integrated database computer
• Construction of electric cabinets, made of the sea-air resistant plastic
• Installation of the electric technology on site at the terminal – including assembly, wiring, and commissioning

Customer Advantages:

• High flexibility and efficiency, based on the integration of the system-alien conveyor channels within the visualization
• Direct unlimited access to besecke's programming and visualization know-how in Riga
• An ideal information flow, thanks to native speakers working for SIA Besecke

Assignment:

• Modernizing and making the robot-controlled packing cells and conveying facility more flexible
• Planning an overriding control concept that would simplify the operation and that could be applied to any type of packaging

besecke's Solution:

• Exchanging the obsolete packing robot for the KR16 robot made by Kuka. Unlike the traditional solutions, the new robots are able to grip different bottle forms, change their gripping direction, and direct the item even around the corner.
• Developing an especially user-friendly visualization and control concept. A multi-panel enables users to alter the parameters as needed (e.g. the bottle size), while it automatically adjusts the packaging pattern.
• Handling the entire project – including the layouts for sensor technology and pneumatics, machine components, construction, commissioning and final training of staff

Customer Advantages:

• The highest degree of flexibility as to packing very different bottles safely without interruptions and placing them inside boxes to be transported onto the palettes.
• Minimal planning efforts, by deploying direction-flexible Kuka robots, as opposed to the linear portal robots that are only able to convey outer packaging straight forward.

View the video

Assignment:

• Engineering the controller technology for an extruder – in cooperation with the B&R company that supplied the controller components
• A special challenge: where seals fill out a 90-degree angle around the door and window frame, the outside rim needs more material than the inner one. This calls for a precise control of the material flow – with the flow speed at 20 meters per minute at fluctuating temperatures

besecke's Solution:

• Development of a software which measures and controls, exactly to the millimeter, the flow rate of the material at the right spots
• Installation of a visualization system that facilitates – for the Meteor's employee operating the machine – hourly monitoring of flow rate values while adjusting them as necessary.

Customer Advantages:

• This besecke system is another step in making production more flexible. It realizes Meteor's future vision – to run around 2,000 different recipes on its production line, with materials being exchanged using a password-protected data stick.